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This work presents the design and implementation of a low-cost (€80) modular in-line monitoring system for estimating pressure at the extrusion nozzle in the FFF desktop 3D printhead (Prusa i3 MK3S model). One-dimensional analytical–numerical models were implemented, considering boundary conditions and geometric constraints of this extrusion printhead type. Two tension springs models 565 and 599 (Fanamol®, Portugal), were configured in parallel, in order to mimic the behavior, the force transducers. Calibration tests were conducted according to ISO 376 (International Organization for Standardization (2011) ISO 376:2011: Metallic materials—calibration of force-proving instruments used for the verification of uniaxial testing machines. ISO, Geneva, Switzerland), using a universal testing machine Multitest 2.5 (Mecmesin®, United Kingdom). The rheological parameters of Polylactic Acid (PLA) ExtralFill Natural (Fillamentum®, Czech Republic), the system’s calibration material, were characterized using a parallel plate rheometer (TA Instruments®, United States of America), with an elongation rate of 5% in the linear regime, at melting temperatures near 200 °C. The Cox-Merz transformation was applied to estimate the rheological properties of the material, particularly the shear rates under steady shear flow. Pseudoplastic behavior during the plasticization process was investigated using the coefficients from the Power Law and Carreau-Yasuda models. The preliminary experimental design considered a hot-end temperature of 200 °C and extrusion speeds from 50 mm/min to 200 mm/min for pressure estimation. The experimental results indicated that the pressures obtained at the extrusion nozzle ranged from 1.27 to 3.32 MPa, for speeds of 50 to 200 mm/min. These values were higher than the results obtained from the numerical model, which presented values ranging from 0.85 to 1.35 MPa. In-line pressure monitoring during the plasticization process in the FFF 3D printhead contributes to the estimation of the material’s thermomechanical and rheological properties during flow, making it a crucial step, especially in the context of data collection for active control techniques and machine learning applications.

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Low-Cost and In-line Monitoring System for Pressure Estimation in a FFF 3D Printhead

  • 章节

  • 发表日期：

    2026年

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  • Dávila Moreira Lopes Silva,
  • Luís Fernando Borges Caldeira,
  • Jorge Lino Alves,
  • Zilda Castro Silveira

摘要

This work presents the design and implementation of a low-cost (€80) modular in-line monitoring system for estimating pressure at the extrusion nozzle in the FFF desktop 3D printhead (Prusa i3 MK3S model). One-dimensional analytical–numerical models were implemented, considering boundary conditions and geometric constraints of this extrusion printhead type. Two tension springs models 565 and 599 (Fanamol®, Portugal), were configured in parallel, in order to mimic the behavior, the force transducers. Calibration tests were conducted according to ISO 376 (International Organization for Standardization (2011) ISO 376:2011: Metallic materials—calibration of force-proving instruments used for the verification of uniaxial testing machines. ISO, Geneva, Switzerland), using a universal testing machine Multitest 2.5 (Mecmesin®, United Kingdom). The rheological parameters of Polylactic Acid (PLA) ExtralFill Natural (Fillamentum®, Czech Republic), the system’s calibration material, were characterized using a parallel plate rheometer (TA Instruments®, United States of America), with an elongation rate of 5% in the linear regime, at melting temperatures near 200 °C. The Cox-Merz transformation was applied to estimate the rheological properties of the material, particularly the shear rates under steady shear flow. Pseudoplastic behavior during the plasticization process was investigated using the coefficients from the Power Law and Carreau-Yasuda models. The preliminary experimental design considered a hot-end temperature of 200 °C and extrusion speeds from 50 mm/min to 200 mm/min for pressure estimation. The experimental results indicated that the pressures obtained at the extrusion nozzle ranged from 1.27 to 3.32 MPa, for speeds of 50 to 200 mm/min. These values were higher than the results obtained from the numerical model, which presented values ranging from 0.85 to 1.35 MPa. In-line pressure monitoring during the plasticization process in the FFF 3D printhead contributes to the estimation of the material’s thermomechanical and rheological properties during flow, making it a crucial step, especially in the context of data collection for active control techniques and machine learning applications.